Optimization of PMDC motor for high overload conditions

The high overload conditions can be very important for a reliable motor drive. The performance of a PMDC motor for extreme conditions was improved by optimizing its magnetic circuit using finite element method in torque calculation and orthogonal arrays. Magnetic field was calculated taking into account non-linear density and effects of current commutation and heating. The electromagnetic torque was determined from magnetic vector potentials of moving conductors. The effect changing each geometric parameter was calculated using a compound procedure for orthogonal arrays. A fast improvement in motor magnetic parts shape was achieved in a moderate number of electromagnetic field and torque calculations.